Flexible graphite packer

ABSTRACT

A packer includes a structure having a first part and a second part, and a plurality of flexible carbon composite particles arranged between the first and second parts.

BACKGROUND

Graphite is an allotrope of carbon and has a layered, planar structure. In each layer, the carbon atoms are arranged in hexagonal arrays or networks through covalent bonds. Different carbon layers however are held together only by weak van der Waals forces.

Graphite has been used in a variety of applications including electronics, atomic energy, hot metal processing, coatings, aerospace and the like due to its excellent thermal and electrical conductivities, lightness, low friction, and high heat and corrosion resistances. However, conventional graphite is not elastic and has low strength, which may limit its further applications such as forming packers employed in a downhole environment.

Packers are used for securing production tubing inside of casing or a liner within a borehole, for example. Packers are also used to create separate zones within a borehole. A packer may take the form of a flexible member mounted to a rigid support body, and carried by a conveyance tubular (such as a production tubing string) downhole to a desired position. The packer is then set or expanded, within an annular space between the conveyance tubular and the outer tubing, casing, or open-hole, and held in place by a packer containment system. The industry would be receptive to improvements in packer technology including a packer formed from a material exhibiting enhanced flexibility, chemical stability, corrosive resistance, as well as high temperature and high pressure resistance properties.

SUMMARY

A packer includes a structure having a first part and a second part, and a plurality of flexible carbon composite particles arranged between the first and second parts.

A subsurface exploration system includes an uphole system and a downhole system operatively connected to the uphole system. The downhole system includes a downhole string having at least one tubular. A packer is supported on the at least one mandrel. The packer includes a structure having a first part and a second part, and a plurality of flexible carbon composite particles arranged between the first and second parts.

A method of setting a packer includes positioning a packer including a metal structure having first and second parts onto a mandrel, shifting at least one of the first and second parts towards another of the first and second parts to compress a plurality of flexible carbon composite particles, urging the plurality of flexible carbon composite particles outwardly of the first and second parts, and guiding the plurality of flexible carbon composite particles towards a wellbore casing.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings wherein like elements are numbered alike in the several Figures:

FIG. 1 is a scanning electron microscopic (“SEM”) image of a composition containing expanded graphite and a micro- or nano-sized binder blended at room temperature and atmospheric pressure;

FIG. 2 is a SEM image of a carbon composite formed from expanded graphite and a micro- or nano-sized binder under high pressure and high temperature conditions according to one embodiment of the disclosure;

FIG. 3 is a SEM image of carbon microstructures according to another embodiment of the disclosure;

FIG. 4 is a schematic illustration of a carbon composite according to an embodiment of the disclosure;

FIG. 5 shows stress-strain curves of (A) natural graphite; (B) expanded graphite; (C) a mixture of expanded graphite and a micro- or nano-sized binder, where the sample is compacted at room temperature and high pressure; (D) a carbon composite according to one embodiment of the disclosure compacted from a mixture of expanded graphite and a micro- or nano-sized binder at a high temperature and a low pressure (also referred to as “soft composite”); and (E) a carbon composite according to another embodiment of the disclosure formed from expanded graphite and a micro- and nano-sized binder under high pressure and high temperature conditions (also referred to as “hard composite”);

FIG. 6 shows loop test results of a carbon composite at different loadings;

FIG. 7 shows hysteresis results of a carbon composite tested at room temperature and 500° F. respectively;

FIG. 8 compares a carbon composite before and after exposing to air at 500° C. for 25 hours;

FIG. 9(A) is a photo of a carbon composite after a thermal shock; FIG. 9(B) illustrates the condition for the thermal shock;

FIG. 10 compares a carbon composite sample (A) before and (B) after exposing to tap water for 20 hours at 200° F., or (C) after exposing to tap water for 3 days at 200° F.;

FIG. 11 compares a carbon composite sample (A) before and (B) after exposing to 15% HCl solution with inhibitor at 200° F. for 20 hours, or (C) after exposing to 15% HCl solution at 200° F. for 3 days;

FIG. 12 shows the sealing force relaxation test results of a carbon composite at 600° F.;

FIG. 13 depicts a subsurface exploration system including a tubular supporting a flexible graphite packer, in accordance with an exemplary embodiment;

FIG. 14 depicts a partial cross-sectional view of the packer of FIG. 1, in accordance with an aspect of an exemplary embodiment;

FIG. 15 depicts a partial cross-sectional view of the packer of FIG. 14 illustrating compression of a metal structure;

FIG. 16 depicts a partial cross-sectional view of the packer of FIG. 15 shifting along the tubular engaging with a wellbore casing;

FIG. 17 depicts a partial cross-sectional view of the packer of FIG. 16 engaged with the wellbore casing;

FIG. 18 depicts a plan view of a packer, in accordance with another aspect of an exemplary embodiment, in an un-deployed configuration; and

FIG. 19 depicts a plan view of a packer of FIG. 17 in a deployed configuration.

DETAILED DESCRIPTION

The inventors hereof have found that carbon composites formed from graphite and micro- or nano-sized binders at high temperatures have improved balanced properties as compared to graphite alone, a composition formed from the same graphite but different binders, or a mixture of the same graphite and the same binder blended at room temperature under atmospheric pressure or high pressures. The new carbon composites have excellent elasticity. In addition, the carbon composites have excellent mechanical strength, heat resistance, and chemical resistance at high temperatures. In a further advantageous feature, the composites keep various superior properties of the graphite such as heat conductivity, electrical conductivity, lubricity, and the alike.

Without wishing to be bound by theory, it is believed that the improvement in mechanical strength is provided by a binding phase disposed between carbon microstructures. There are either no forces or only weak Van der Waals forces exist between the carbon microstructures thus the graphite bulk materials have weak mechanical strength. At high temperatures, the micro- and nano-sized binder liquefies and is dispersed evenly among carbon microstructures. Upon cooling, the binder solidifies and forms a binding phase binding the carbon nanostructures together through mechanical interlocking.

Further without wishing to be bound by theory, for the composites having both improved mechanical strength and improved elasticity, it is believed that the carbon microstructures themselves are laminar structures having spaces between the stacked layers. The binder only selectively locks the microstructures at their boundaries without penetrating the microstructures. Thus the unbounded layers within the microstructures provide elasticity and the binding phase disposed between the carbon microstructures provides mechanical strength.

The carbon microstructures are microscopic structures of graphite formed after compressing graphite into highly condensed state. They comprise graphite basal planes stacked together along the compression direction. As used herein, carbon basal planes refer to substantially flat, parallel sheets or layers of carbon atoms, where each sheet or layer has a single atom thickness. The graphite basal planes are also referred to as carbon layers. The carbon microstructures are generally flat and thin. They can have different shapes and can also be referred to as micro-flakes, micro-discs and the like. In an embodiment, the carbon microstructures are substantially parallel to each other.

There are two types of voids in the carbon composites—voids or interstitial spaces between carbon microstructures and voids within each individual carbon microstructures. The interstitial spaces between the carbon microstructures have a size of about 0.1 to about 100 microns, specifically about 1 to about 20 microns whereas the voids within the carbon microstructures are much smaller and are generally between about 20 nanometers to about 1 micron, specifically about 200 nanometers to about 1 micron. The shape of the voids or interstitial spaces is not particularly limited. As used herein, the size of the voids or interstitial spaces refers to the largest dimension of the voids or interstitial spaces and can be determined by high resolution electron or atomic force microscope technology.

The interstitial spaces between the carbon microstructures are filled with a micro- or nano-sized binder. For example, a binder can occupy about 10% to about 90% of the interstitial spaces between the carbon microstructures. However, the binder does not penetrate the individual carbon microstructures and the voids within carbon microstructures are unfilled, i.e., not filled with any binder. Thus the carbon layers within the carbon microstructures are not locked together by a binder. Through this mechanism, the flexibility of the carbon composite, particularly, expanded carbon composite can be preserved.

The carbon microstructures have a thickness of about 1 to about 200 microns, about 1 to about 150 microns, about 1 to about 100 microns, about 1 to about 50 microns, or about 10 to about 20 microns. The diameter or largest dimension of the carbon microstructures is about 5 to about 500 microns or about 10 to about 500 microns. The aspect ratio of the carbon microstructures can be about 10 to about 500, about 20 to about 400, or about 25 to about 350. In an embodiment, the distance between the carbon layers in the carbon microstructures is about 0.3 nanometers to about 1 micron. The carbon microstructures can have a density of about 0.5 to about 3 g/cm³, or about 0.1 to about 2 g/cm³.

As used herein, graphite includes natural graphite, synthetic graphite, expandable graphite, expanded graphite, or a combination comprising at least one of the foregoing. Natural graphite is graphite formed by Nature. It can be classified as “flake” graphite, “vein” graphite, and “amorphous” graphite. Synthetic graphite is a manufactured product made from carbon materials. Pyrolytic graphite is one form of the synthetic graphite. Expandable graphite refers to graphite having intercallant materials inserted between layers of natural graphite or synthetic graphite. A wide variety of chemicals have been used to intercalate graphite materials. These include acids, oxidants, halides, or the like. Exemplary intercallant materials include sulfuric acid, nitric acid, chromic acid, boric acid, SO₃, or halides such as FeCl₃, ZnCl₂, and SbCl₅. Upon heating, the intercallant is converted from a liquid or solid state to a gas phase. Gas formation generates pressure which pushes adjacent carbon layers apart resulting in expanded graphite. The expanded graphite particles are vermiform in appearance, and are therefore commonly referred to as worms.

Advantageously, the carbon composites comprise expanded graphite microstructures. Compared with other forms of the graphite, expanded graphite has high flexibility and compression recovery, and larger anisotropy. The composites formed from expanded graphite and micro- or nano-sized binder under high pressure and high temperature conditions can thus have excellent elasticity in addition to desirable mechanical strength.

In the carbon composites, the carbon microstructures are held together by a binding phase. The binding phase comprises a binder which binds carbon microstructures by mechanical interlocking. Optionally, an interface layer is formed between the binder and the carbon microstructures. The interface layer can comprise chemical bonds, solid solutions, or a combination thereof. When present, the chemical bonds, solid solutions, or a combination thereof may strengthen the interlocking of the carbon microstructures. It is appreciated that the carbon microstructures may be held together by both mechanical interlocking and chemical bonding. For example the chemical bonding, solid solution, or a combination thereof may be formed between some carbon microstructures and the binder or for a particular carbon microstructure only between a portion of the carbon on the surface of the carbon microstructure and the binder. For the carbon microstructures or portions of the carbon microstructures that do not form a chemical bond, solid solution, or a combination thereof, the carbon microstructures can be bounded by mechanical interlocking. The thickness of the binding phase is about 0.1 to about 100 microns or about 1 to about 20 microns. The binding phase can form a continuous or discontinuous network that binds carbon microstructures together.

Exemplary binders include SiO₂, Si, B, B₂O₃, a metal, an alloy, or a combination comprising at least one of the foregoing. The metal can be aluminum, copper, titanium, nickel, tungsten, chromium, iron, manganese, zirconium, hafnium, vanadium, niobium, molybdenum, tin, bismuth, antimony, lead, cadmium, and selenium. The alloy includes the alloys of aluminum, copper, titanium, nickel, tungsten, chromium, iron, manganese, zirconium, hafnium, vanadium, niobium, molybdenum, tin, bismuth, antimony, lead, cadmium, and selenium. In an embodiment, the binder comprises copper, nickel, chromium, iron, titanium, an alloy of copper, an alloy of nickel, an alloy of chromium, an alloy of iron, an alloy of titanium, or a combination comprising at least one of the foregoing metal or metal alloy. Exemplary alloys include steel, nickel-chromium based alloys such as Inconel*, and nickel-copper based alloys such as Monel alloys. Nickel-chromium based alloys can contain about 40-75% of Ni, about 10-35% of Cr. The nickel-chromium based alloys can also contain about 1 to about 15% of iron. Small amounts of Mo, Nb, Co, Mn, Cu, Al, Ti, Si, C, S, P, B, or a combination comprising at least one of the foregoing can also be included in the nickel-chromium based alloys. Nickel-copper based alloys are primarily composed of nickel (up to about 67%) and copper. The nickel-copper based alloys can also contain small amounts of iron, manganese, carbon, and silicon. These materials can be in different shapes, such as particles, fibers, and wires. Combinations of the materials can be used.

The binder used to make the carbon composite is micro- or nano-sized. In an embodiment, the binder has an average particle size of about 0.05 to about 10 microns, specifically, about 0.5 to about 5 microns, more specifically about 0.1 to about 3 microns. Without wishing to be bound by theory, it is believed that when the binder has a size within these ranges, it disperses uniformly among the carbon microstructures.

When an interface layer is present, the binding phase comprises a binder layer comprising a binder and an interface layer bonding one of the at least two carbon microstructures to the binder layer. In an embodiment, the binding phase comprises a binder layer, a first interface layer bonding one of the carbon microstructures to the binder layer, and a second interface layer bonding the other of the microstructures to the binder layer. The first interface layer and the second interface layer can have the same or different compositions.

The interface layer comprises a C-metal bond, a C—B bond, a C—Si bond, a C—O—Si bond, a C—O-metal bond, a metal carbon solution, or a combination comprising at least one of the foregoing. The bonds are formed from the carbon on the surface of the carbon microstructures and the binder.

In an embodiment, the interface layer comprises carbides of the binder. The carbides include carbides of aluminum, titanium, nickel, tungsten, chromium, iron, manganese, zirconium, hafnium, vanadium, niobium, molybdenum, or a combination comprising at least one of the foregoing. These carbides are formed by reacting the corresponding metal or metal alloy binder with the carbon atoms of the carbon microstructures. The binding phase can also comprise SiC formed by reacting SiO₂ or Si with the carbon of carbon microstructures, or B₄C formed by reacting B or B₂O₃ with the carbon of the carbon microstructures. When a combination of binder materials is used, the interface layer can comprise a combination of these carbides. The carbides can be salt-like carbides such as aluminum carbide, covalent carbides such as SiC, B₄C, interstitial carbides such as carbides of the group 4, 5, and 5 transition metals, or intermediate transition metal carbides, for example the carbides of Cr, Mn, Fe, Co, and Ni.

In another embodiment, the interface layer comprises a solid solution of carbon and the binder. Carbon have solubility in certain metal matrix or at certain temperature range, which helps both wetting and binding of metal phase onto carbon microstructures. Through heat-treatment, high solubility of carbon in metal can be maintained at low temperature. These metals include Co, Fe, La, Mn, Ni, or Cu. The binder layer can also comprises a combination of solid solutions and carbides.

The carbon composites comprise about 20 to about 95 wt. %, about 20 to about 80 wt. %, or about 50 to about 80 wt. % of carbon, based on the total weight of the composites. The binder is present in an amount of about 5 wt. % to about 75 wt. % or about 20 wt. % to about 50 wt. %, based on the total weight of the composites. In the carbon composites, the weight ratio of carbon relative to the binding is about 1:4 to about 20:1, or about 1:4 to about 4:1, or about 1:1 to about 4:1.

FIG. 1 is a SEM image of a composition containing expanded graphite and a micro- or nano-sized binder blended at room temperature and atmospheric pressure. As shown in FIG. 1, the binder (white area) is only deposited on the surface of some of the expanded graphite worms.

FIG. 2 is a SEM image of a carbon composite formed from expanded graphite and a micro- or nano-sized binder under high pressure and high temperature conditions. As shown in FIG. 2, a binding phase (light area) is evenly distributed between the expanded graphite microstructures (dark area).

A SEM image of carbon graphite microstructures are shown in FIG. 3. An embodiment of a carbon composite is illustrated in FIG. 4. As shown in FIG. 4, the composite comprises carbon microstructures 1 and binding phase 2 locking the carbon microstructures. The binding phase 2 comprises binder layer 3 and an optional interface layer 4 disposed between the binder layer and the carbon microstructures. The carbon composite contains interstitial space 5 among carbon microstructures 1. Within carbon microstructures, there are unfilled voids 6.

The carbon composites can optionally comprise a filler. Exemplary filler includes carbon fibers, carbon black, mica, clay, glass fiber, ceramic fibers, and ceramic hollow structures. Ceramic materials include SiC, Si₃N₄, SiO₂, BN, and the like. The filler can be present in an amount of about 0.5 to about 10 wt. % or about 1 to about 8%.

The composites can have any desired shape including a bar, block, sheet, tubular, cylindrical billet, toroid, powder, pellets, or other form that may be machined, formed or otherwise used to form useful articles of manufacture. The sizes or the dimension of these forms are not particularly limited. Illustratively, the sheet has a thickness of about 10 μm to about 10 cm and a width of about 10 mm to about 2 m. The powder comprises particles having an average size of about 10 μm to about 1 cm. The pellets comprise particles having an average size of about 1 cm to about 5 cm.

One way to form the carbon composites is to compress a combination comprising carbon and a micro- or nano-sized binder to provide a green compact by cold pressing; and to compressing and heating the green compact thereby forming the carbon composites. In another embodiment, the combination can be pressed at room temperature to form a compact, and then the compact is heated at atmospheric pressure to form the carbon composite. These processes can be referred to as two-step processes. Alternatively, a combination comprising carbon and a micro- or nano-sized binder can be compressed and heated directly to form the carbon composites. The process can be referred to as a one-step process.

In the combination, the carbon such as graphite is present in an amount of about 20 wt. % to about 95 wt. %, about 20 wt. % to about 80 wt. %, or about 50 wt. % to about 80 wt. %, based on the total weight of the combination. The binder is present in an amount of about 5 wt. % to about 75 wt. % or about 20 wt. % to about 50 wt. %, based on the total weight of the combination. The graphite in the combination can be in the form of chip, powder, platelet, flake, or the like. In an embodiment, the graphite is in the form of flakes having a diameter of about 50 microns to about 5,000 microns, preferably about 100 to about 300 microns. The graphite flakes can have a thickness of about 1 to about 5 microns. The density of the combination is about 0.01 to about 0.05 g/cm³, about 0.01 to about 0.04 g/cm³, about 0.01 to about 0.03 g/cm³ or about 0.026 g/cm³. The combination can be formed by blending the graphite and the micro- or nano-sized binder via any suitable methods known in the art. Examples of suitable methods include ball mixing, acoustic mixing, ribbon blending, vertical screw mixing, and V-blending.

Referring to the two-step process, cold pressing means that the combination comprising the graphite and the micro-sized or nano-sized binder is compressed at room temperature or at an elevated temperature as long as the binder does not significantly bond with the graphite microstructures. In an embodiment, greater than about 80 wt. %, greater than about 85 wt. %, greater than about 90 wt. %, greater than about 95 wt. %, or greater than about 99 wt. % of the microstructures are not bonded in the green compact. The pressure to form the green compact can be about 500 psi to about 10 ksi and the temperature can be about 20° C. to about 200° C. The reduction ratio at this stage, i.e., the volume of the green compact relative to the volume of the combination, is about 40% to about 80%. The density of the green compact is about 0.1 to about 5 g/cm³, about 0.5 to about 3 g/cm³, or about 0.5 to about 2 g/cm³.

The green compact can be heated at a temperature of about 350° C. to about 1200° C., specifically about 800° C. to about 1200° C. to form the carbon composites. In an embodiment, the temperature is above the melting point of the binder, for example, about 20° C. to about 100° C. higher or about 20° C. to about 50° C. higher than the melting point of the binder. When the temperature is higher, the binder becomes less viscose and flows better, and less pressure may be required in order for the binder to be evenly distributed in the voids between the carbon microstructures. However, if the temperature is too high, it may have detrimental effects to the instrument.

The temperature can be applied according to a predetermined temperature schedule or ramp rate. The means of heating is not particularly limited. Exemplary heating methods include direct current (DC) heating, induction heating, microwave heating, and spark plasma sintering (SPS). In an embodiment, the heating is conducted via DC heating. For example, the combination comprising the graphite and the micro- or nano-sized binder can be charged with a current, which flows through the combination generating heat very quickly. Optionally, the heating can also be conducted under an inert atmosphere, for example, under argon or nitrogen. In an embodiment, the green compact is heated in the presence of air.

The heating can be conducted at a pressure of about 500 psi to about 30,000 psi or about 1000 psi to about 5000 psi. The pressure can be a superatmospheric pressure or a subatmospheric pressure. Without wishing to be bound by theory, it is believed that when a superatmospheric pressure is applied to the combination, the micro- or nano-sized binder is forced into the voids between carbon microstructures through infiltration. When a subatmospheric pressure is applied to the combination, the micro- or nano-sized binder can also be forced into the voids between the carbon microstructures by capillary forces.

In an embodiment, the desirable pressure to form the carbon composites is not applied all at once. After the green compact is loaded, a low pressure is initially applied to the composition at room temperature or at a low temperature to close the large pores in the composition. Otherwise, the melted binder may flow to the surface of the die. Once the temperature reaches the predetermined maximum temperature, the desirable pressure required to make the carbon composites can be applied. The temperature and the pressure can be held at the predetermined maximum temperature and the predetermined maximum temperature for 5 minutes to 120 minutes.

The reduction ratio at this stage, i.e. the volume of the carbon composite relative to the volume of the green compact, is about 10% to about 70% or about 20 to about 40%. The density of the carbon composite can be varied by controlling the degree of compression. The carbon composites have a density of about 0.5 to about 10 g/cm³, about 1 to about 8 g/cm³, about 1 to about 6 g/cm³, about 2 to about 5 g/cm³, about 3 to about 5 g/cm³, or about 2 to about 4 g/cm³.

Alternatively, also referring to a two-step process, the combination can be first pressed at room temperature and a pressure of about 500 psi to 30,000 psi to form a compact; the compact can be further heated at a temperature higher than the melting point of the binder to make the carbon composite. In an embodiment, the temperature can be about 20° C. to about 100° C. higher or about 20° C. to about 50° C. higher than the melting point of the binder. The heating can be conducted at atmospheric pressure.

In another embodiment, the carbon composite can be made from the combination of the graphite and the binder directly without making the green compact. The pressing and the heating can be carried out simultaneously. Suitable pressures and temperatures can be the same as discussed herein for the second step of the two-step process.

Hot pressing is a process that applies temperature and pressure simultaneously. It can be used in both the one-step and the two-step processes to make carbon composites.

The carbon composites can be made in a mold through a one-step or a two-step process. The obtained carbon composites can be further machined or shaped to form a bar, block, tubular, cylindrical billet, or toroid. Machining includes cutting, sawing, ablating, milling, facing, lathing, boring, and the like using, for example, a miller, saw, lathe, router, electric discharge machine, and the like. Alternatively, the carbon composite can be directly molded to the useful shape by choosing the molds having the desired shape.

Sheet materials such as web, paper, strip, tape, foil, mat or the like can also be made via hot rolling. In an embodiment, the carbon composite sheets made by hot rolling can be further heated to allow the binder to effectively bond the carbon microstructures together.

Carbon composite pellets can be made by extrusion. For example, a combination of the graphite and the micro- or nano-sized binder can be first loaded in a container. Then combination is pushed into an extruder through a piston. The extrusion temperature can be about 350° C. to about 1400° C. or about 800° C. to about 1200° C. In an embodiment, the extrusion temperature is higher than the melting point of the binder, for example, about 20 to about 50° C. higher than the melting point of the binder. In an embodiment, wires are obtained from the extrusion, which can be cut to form pellets. In another embodiment, pellets are directly obtained from the extruder. Optionally, a post treatment process can be applied to the pellets. For example, the pellets can be heated in a furnace above the melting temperature of the binder so that the binder can bond the carbon microstructures together if the carbon microstructures have not been bonded or not adequately bonded during the extrusion.

Carbon composite powder can be made by milling carbon composites, for example a solid piece, through shearing forces (cutting forces). It is noted that the carbon composites should not be smashed. Otherwise, the voids within the carbon microstructures may be destroyed thus the carbon composites lose elasticity.

The carbon composites have a number of advantageous properties for use in a wide variety of applications. In an especially advantageous feature, by forming carbon composites, both the mechanical strength and the elastomeric properties are improved.

To illustrate the improvement of elastic energy achieved by the carbon composites, the stress-strain curves for the following samples are shown in FIG. 5: (A) natural graphite, (B) expanded graphite, (C) a mixture of expanded graphite and a micro- or nano-sized binder formed at room temperature and atmospheric pressure, (D) a mixture of expanded graphite and a micro- or nano-sized binder formed by at a high temperature and atmospheric pressure; and (E) a carbon composite formed from expanded graphite and a micro- and nano-sized binder under high pressure and high temperature conditions. For the natural graphite, the sample was made by compressing natural graphite in a steel die at a high pressure. The expanded graphite sample was also made in a similar manner.

As shown in FIG. 5, the natural graphite has a very low elastic energy (area under the stress-strain curve) and is very brittle. The elastic energy of expanded graphite and the elastic energy of the mixture of expanded graphite and a micro- or nano-sized binder compacted at room temperature and high pressure is higher than that of the natural graphite. Conversely, both the hard and soft carbon composites of the disclosure exhibit significantly improved elasticity shown by the notable increase of the elastic energy as compared to the natural graphite alone, the expanded graphite alone, and the mixture of expanded graphite and binder compacted at room temperature and high pressure. In an embodiment, the carbon composites have an elastic elongation of greater than about 4%, greater than about 6%, or between about 4% and about 40%.

The elasticity of the carbon composites is further illustrated in FIGS. 6 and 7. FIG. 6 shows loop test results of a carbon composite at different loadings. FIG. 7 shows hysteresis results of a carbon composite tested at room temperature and 500° F. respectively. As shown in FIG. 7, the elasticity of the carbon composite is maintained at 500° F.

In addition to mechanical strength and elasticity, the carbon composites can also have excellent thermal stability at high temperatures. FIG. 8 compares a carbon composite before and after exposing to air at 500° C. for 5 days. FIG. 9(A) is a photo of a carbon composite sample after a thermo shock for 8 hours. The condition for the thermal shock is shown in FIG. 9(B). As shown in FIGS. 8 and 9(A), there are no changes to the carbon composite sample after exposing to air at 500° C. for 25 hours or after the thermal shock. The carbon composites can have high thermal resistance with a range of operation temperatures from about −65° F. up to about 1200° F., specifically up to about 1100° F., and more specifically about 1000° F.

The carbon composites can also have excellent chemical resistance at elevated temperatures. In an embodiment, the composite is chemically resistant to water, oil, brines, and acids with resistance rating from good to excellent. In an embodiment, the carbon composites can be used continuously at high temperatures and high pressures, for example, about 68° F. to about 1200° F., or about 68° F. to about 1000° F., or about 68° F. to about 750° F. under wet conditions, including basic and acidic conditions. Thus, the carbon composites resist swelling and degradation of properties when exposed to chemical agents (e.g., water, brine, hydrocarbons, acids such as HCl, solvents such as toluene, etc.), even at elevated temperatures of up to 200° F., and at elevated pressures (greater than atmospheric pressure) for prolonged periods. The chemical resistance of the carbon composite is illustrated in FIGS. 10 and 11. FIG. 10 compares a carbon composite sample before and after exposing to tap water for 20 hours at 200° F., or after exposing to tap water for 3 days at 200° F. As shown in FIG. 10, there are no changes to the sample. FIG. 11 compares a carbon composite sample before and after exposing to 15% HCl solution with inhibitor at 200° F. for 20 hours, or after exposing to 15% HCl solution at 200° F. for 3 days. Again, there are no changes to the carbon composite sample.

The carbon composites are medium hard to extra hard with harness from about 50 in SHORE A up to about 75 in SHORE D scale.

As a further advantageous feature, the carbon composites have stable sealing force at high temperatures. The stress decay of components under constant compressive strain is known as compression stress relaxation. A compression stress relaxation test also known as sealing force relaxation test measures the sealing force exerted by a seal or O-ring under compression between two plates. It provides definitive information for the prediction of the service life of materials by measuring the sealing force decay of a sample as a function of time, temperature and environment. FIG. 12 shows the sealing force relaxation test results of a carbon composite sample 600° F. As shown in FIG. 12, the sealing force of the carbon composite is stable at high temperatures. In an embodiment, the sealing force of a sample of the composite at 15% strain and 600° F. is maintained at about 5800 psi without relaxation for at least 20 minutes.

The carbon composites described above may be useful for preparing articles for a wide variety of applications including, but not limited to electronics, hot metal processing, coatings, aerospace, automotive, oil and gas, and marine applications. Exemplary articles include seals, bearings, bearing seats, packers, valves, engines, reactors, cooling systems, and heat sinks. Thus, in an embodiment, an article comprises the carbon composites. The carbon composites may be used to form all or a portion of a downhole article as will be discussed more fully below.

A subsurface exploration system, in accordance with an exemplary embodiment, is indicated generally at 200, in FIG. 13. Subsurface exploration system 200 includes an uphole system 204 operatively connected to a downhole system 206. Uphole system 204 may include pumps 208 that aid in completion and/or extraction processes as well as a fluid storage portion 210. Fluid storage portion 210 may contain a fluid that is introduced into downhole system 206. Downhole system 206 may include a downhole string 220 that is extended into a wellbore 221 formed in formation 222. Wellbore 221 may include a wellbore casing 223. Downhole string 220 may include a number of connected downhole tubulars 224. One of tubulars 224 may support a mandrel 226 which, in turn, may support a packer 228. Mandrel 226 may include a hollow or solid cross-section and an angled surface section 230 (FIG. 14) adjacent packer 228. Packer 228 may be positioned to isolate one portion of wellbore 221 from another portion of wellbore 221 or as part of a CO2 sequestration system.

As shown in FIG. 14, packer 228 includes a structure 240 having a first backup or part 242 and a second backup or part 244. First part 242 includes a first or inner end 250 arranged adjacent mandrel 226 and a second, cantilevered outer end 252. Second part 244 includes a first or inner end 254 arranged adjacent tubular 224 and a second, cantilevered outer end 256. First and second parts 242 and 244 extend annularly about mandrel 226. A plurality of flexible carbon composite particles 260 is arranged between first and second parts 242 and 244. Structure 240 is formed from an expandable metal. It should be understood that the plurality of flexible carbon composite particles 260 are formed from the carbon composites described above.

In further accordance with an exemplary embodiment, packer 228 also includes a flexible membrane 270 that extends between first and second parts 242 and 244. More specifically, flexible membrane 270 includes a first end section 274 coupled to first part 242, a second end section 276 coupled to second part 244, and an intermediate portion 278. Intermediate portion 278 extends between first end section 274 and second end section 276. In accordance with an aspect of an exemplary embodiment, flexible membrane 270 may be formed from a woven material including, for example, carbon fibers, metal wires, asbestos fibers, metal fibers, expandable carbon composite fibers, and the like, that may withstand a high temperature, high pressure (HTHP) environment such as found downhole. The woven material should also be capable of withstanding a corrosive downhole environment. In accordance with another aspect of an exemplary embodiment, flexible membrane 270 may be formed from a material, such as a polymer fiber, that may degrade or decompose when exposed to a downhole environment or injected chemicals for that purpose.

In accordance with an aspect of an exemplary embodiment, after being positioned downhole, a first force 320 may be applied to first part 242 and a second, opposing force 324 may be applied to second part 244, as shown in FIG. 15. First and second forces 320 and 324 guide first and second parts 242 and 244 toward each other along mandrel 226. Of course, it should be understood that one of first and second parts 242 and 244 may be moved toward another of first and second parts 242 and 244. As first and second parts 242 and 244 are moved toward each other, plurality of flexible carbon composite particles 260 is compressed forming a bulge region 326.

Another force 328 shifts structure 240 along mandrel 226, as shown in FIG. 16. Force 328 guides structure 240 along angled surface section 230 causing bulge region 326 to contact wellbore casing 223. Further shifting along angled surface section 230 results in a compressive force being imparted to plurality of flexible carbon composite particles 260, as shown in FIG. 17. The compressive force causes plurality of flexible carbon composite particles 260 to deform. As plurality of flexible carbon composite particles 260 include relatively slippery surfaces, the deformation results in little or no tension being created between flexible carbon composite particles 260 during compression. As first and second parts 242 and 244 compress against wellbore casing 223, plurality of flexible carbon composite particles 260 deform further and become more compressed. As plurality of carbon composite particles 260 includes relatively slippery surfaces, the deformation results in the formation of a flexible carbon composite compact 350 that is substantially tension free. Further, plurality of flexible carbon composite particles 260 possess high malleability and elasticity properties that result in a resilient, corrosive resistant, HTHP seal to isolate portions of wellbore 221.

Reference will now follow to FIGS. 18 and 19, wherein like numbers represent corresponding parts in the respective views, in describing a packer 360 formed in accordance with another aspect of an exemplary embodiment. Packer 360 includes a structure 370 including a first backup or part 372 and a second backup or part 374. First part 372 includes a first or inner end 380 arranged adjacent mandrel 226 and a second, cantilevered outer end 382. Second part 374 includes a first or inner end 384 arranged adjacent tubular 224 and a second, cantilevered outer end 386. First and second parts 372 and 374 extend annularly about mandrel 226.

Packer 360 also includes a flexible membrane 390 extending between first and second parts 372 and 374. Flexible membrane 390 is formed in a tube 394 having an interior portion 396. Tube 394 extends or wraps about tubular 224 in a series of coils 398. In accordance with an aspect of an exemplary embodiment, coils 398 are joined to reduce leakage. However, it should be understood that coils 398 may also be separate from one another. In either case, tube 394 may be flexible. In a manner similar to that described above, tube 394 may be formed from a woven material including, for example, carbon fibers, metal wires, asbestos fibers, metal fibers, expandable carbon composite fibers, and the like, that may withstand a high temperature, high pressure (HTHP) environment such as found downhole. The woven material should also be capable of withstanding a corrosive downhole environment.

A plurality of flexible carbon composite particles 420 is within interior portion 396. With this arrangement, a force 440 is exerted on first part 372. Force 440 guides first part 372 toward second part 374 compressing coils 398. As coils 398 compress, first and/or second parts 372 and 374 shift along a surface 450 of mandrel 226 causing flexible membrane 390 to expand. Second part 374 may be fixed or constrained by a stop 470 causing flexible membrane 390 and the plurality of flexible carbon composite particles 420 to compress and form a seal against wellbore casing 223. Of course, it should be understood that one of first and second parts 372 and 374 may be also guided along an angled surface section causing coils 398 to expand radially outwardly and seat against wellbore casing 223. Once seated, a second stop or body lock 474 is secured to surface 450 locking first part 372 in place to tubular 224 to isolate a first part of formation 222 from a second part of formation 222.

All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The suffix “(s)” as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including at least one of that term (e.g., the colorant(s) includes at least one colorants). “Or” means ‘and/or.” “Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event occurs and instances where it does not. As used herein, “combination” is inclusive of blends, mixtures, alloys, reaction products, and the like. All references are incorporated herein by reference.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).

While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. 

1. A packer comprising: a structure including a first part and a second part; and a plurality of flexible carbon composite particles arranged between the first and second parts.
 2. The packer according to claim 1, further comprising: a flexible membrane extending between the first and second parts.
 3. The packer according to claim 2, wherein the flexible membrane is formed from a woven material.
 4. The packer according to claim 3, wherein the woven material includes one or more of a carbon fiber; a metal wire; an asbestos material; a metal fiber; or a flexible graphite fiber.
 5. The packer according to claim 2, wherein the flexible membrane is formed from a degradable material.
 6. The packer according to claim 5, wherein the degradable material comprises a polymer fiber.
 7. The packer according to claim 2, wherein the flexible membrane comprises a tube, the plurality of carbon composite particles being encased in the tube.
 8. A subsurface exploration system comprising: an uphole system; a downhole system operatively connected to the uphole system, the downhole system including a downhole string having at least one mandrel; and a packer supported on the at least one mandrel, the packer comprising: a structure including a first part and a second part; and a plurality of flexible carbon composite particles arranged between the first and second parts.
 9. The resource exploration system according to claim 8, further comprising: a flexible membrane extending between the first and second parts.
 10. The subsurface exploration system according to claim 9, wherein the flexible membrane is formed from a woven material.
 11. The subsurface exploration system according to claim 10, wherein the woven material includes one or more of a carbon fiber; a metal wire; an asbestos material; a metal fiber; or a flexible graphite fiber.
 12. The subsurface exploration system according to claim 9, wherein the flexible membrane is formed from a degradable material.
 13. The subsurface exploration system according to claim 12, wherein the degradable material comprises a polymer fiber.
 14. The subsurface exploration system according to claim 9, wherein the flexible membrane comprises a tube arranged in a coil extending about the at least one tubular, the plurality of flexible carbon composite particles being encased in the tube.
 15. A method of setting a packer comprising: positioning a packer including a metal structure including first and second parts onto a mandrel; shifting at least one of the first and second parts towards another of the first and second parts to compress a plurality of flexible carbon composite particles; urging the plurality of flexible carbon composite particles outwardly of the first and second parts; and guiding the plurality of flexible carbon composite particles towards a wellbore casing.
 16. The method of claim 15, further comprising: constraining the plurality of flexible carbon composite particles between the first and second parts with a flexible membrane.
 17. The method of claim 15, wherein urging the plurality of flexible carbon composite particles outwardly of the first and second parts includes expanding the flexible membrane.
 18. The method of claim 16, wherein constraining the plurality of flexible carbon composite particles between the first and second parts with the flexible membrane includes positioning a flexible membrane formed from one of a woven material and a degradable material between the first and second parts.
 19. The method of claim 15, wherein guiding the plurality of flexible carbon composite particles toward the wellbore casing includes shifting the first and second parts along an angled surface section of the mandrel.
 20. The method of claim 15, wherein guiding the plurality of flexible carbon composite particles toward the wellbore casing includes compressing the plurality of flexible carbon composite particles encased in a hollow tube formed by the flexible membrane coiled about the mandrel. 